Inductor with an electrode structure

Abstract

A method to form an electrical component, comprising: overlaying a conductive and adhesive layer on a body and covering a first portion of a terminal part of a conductive element, wherein a second portion of the terminal part of the conductive element is not covered by the conductive and adhesive layer; and overlaying at least one metal layer on the conductive and adhesive layer and covering the second portion of the terminal part of the conductive element, wherein the at least one metal layer is electrically connected to the second portion of the terminal part of the conductive element for electrically connecting with an external circuit.

What is claimed is: 
     
       1. A method to form an electrical component, comprising:
 providing a body, wherein a conductive element is disposed in the body, wherein a terminal part of the conductive element is exposed outside of the body with said terminal part exposed outside of the body being entirely disposed on a bottom surface of the body; 
 overlaying a conductive and adhesive layer on the body and covering a first portion of the terminal part of the conductive element, wherein a second portion of the terminal part of the conductive element is not covered by the conductive and adhesive layer; and 
 overlaying at least one metal layer on the conductive and adhesive layer and covering the second portion of the terminal part of the conductive element with a portion of the conductive and adhesive layer being located between the at least one metal layer and the first portion of the terminal part of the conductive element and in contact with the at least one metal layer and the first portion of the terminal part of the conductive element, wherein the at least one metal layer is in contact with and electrically connected to the second portion of the terminal part disposed on the bottom surface of the body for electrically connecting with an external circuit. 
 
     
     
       2. The method of  claim 1 , further comprising disposing an additional metal layer on the body to encapsulate the terminal part of the conductive element, wherein the conductive and adhesive layer overlays on a top surface of the additional metal layer. 
     
     
       3. The method of  claim 1 , wherein the at least one metal layer comprises a first metal layer and a second metal layer, wherein the first metal layer overlays on the conductive and adhesive layer and the second portion of the terminal part of the conductive element; and the second metal layer overlays on the first metal layer for electrically connecting with an external circuit. 
     
     
       4. The method of  claim 3 , wherein the conductive and adhesive layer is made by mixing Ag powder with epoxy resin, the first metal layer is made of Ni and the second metal layer is made of Sn. 
     
     
       5. The method of  claim 3 , wherein the conductive and adhesive layer is made by mixing the Ag powder with epoxy resin, the first metal layer is made of Cu and the second metal layer is made of Sn. 
     
     
       6. The method of  claim 3 , wherein the first metal layer and the second metal layer are made by electroplating. 
     
     
       7. The method of  claim 1 , wherein the conductive and adhesive layer overlays on the first portion and a third portion of the terminal part of the conductive element, wherein the second portion is located between the first portion and the third portion. 
     
     
       8. The method of  claim 1 , wherein a third portion of the terminal part of the conductive element is covered by the conductive and adhesive, wherein the second portion of the terminal part of the conductive element is located between the first portion and the third portion of the terminal part of the conductive element. 
     
     
       9. The method of  claim 1 , wherein a recess is formed on a top surface of the body, wherein the terminal part of the conductive element is disposed in the recess. 
     
     
       10. The method of  claim 1 , wherein the electrical component is an inductor. 
     
     
       11. The method of  claim 1 , wherein the electrical component is a choke. 
     
     
       12. The method of  claim 1 , wherein the electrical component is an inductor and the conductive element is a coil, and the coil is disposed in the body with the terminal part of the coil disposed in a recess on a surface of the body. 
     
     
       13. The method of  claim 1 , wherein the electrical component is an inductor and the conductive element is a coil, wherein the body is a magnetic body and the coil is disposed in the magnetic body with the terminal part of the coil disposed in a recess on the bottom surface of the magnetic body, wherein the magnetic body comprises a T-core having a pillar, wherein the coil surrounds the pillar and the terminal part of the coil disposed in a recess on the bottom surface of the magnetic body via a side surface of the T-core. 
     
     
       14. A method to form an inductor, comprising:
 providing a magnetic body, wherein a coil is disposed in the magnetic body, wherein a terminal part of the coil is exposed outside of the magnetic body with said terminal part exposed outside of the magnetic body being entirely disposed on a bottom surface of the magnetic body; 
 overlaying a conductive and adhesive layer on the magnetic body and a first portion of the terminal part of the coil, wherein a second portion of the terminal part of the coil is not overlaid by the conductive and adhesive layer; and 
 overlaying at least one metal layer on the conductive and adhesive layer and the second portion of the terminal part of the coil with a portion of the conductive and adhesive layer being located between the at least one metal layer and the first portion of the terminal part of the coil and in contact with the at least one metal layer and the first portion of the terminal part of the coil, wherein the at least one metal layer is in contact with and electrically connected to the second portion of the terminal part disposed on the bottom surface of the magnetic body for electrically connecting with an external circuit. 
 
     
     
       15. The method of  claim 14 , wherein the magnetic body comprises a T-core having a pillar, wherein the coil surrounds the pillar and the terminal part of the coil disposed in a first recess on a bottom surface of the magnetic body via a side surface of the T-core. 
     
     
       16. The method of  claim 14 , wherein the magnetic body comprises a T-core having a pillar and a plate connected to the pillar, wherein the coil surrounds the pillar and the terminal part of the coil is disposed in a recess on the plate. 
     
     
       17. A method to form an inductor, comprising:
 forming a magnetic body, wherein a recess is formed in the magnetic body, wherein a coil formed by an insulated conductive wire is disposed in the magnetic body, wherein a terminal part of the insulated conductive wire is placed on a bottom surface of the recess, wherein a first portion of the terminal part of the insulated conductive wire is embedded inside the recess, wherein an internal conductor of a second portion of the terminal part of the insulated conductive wire is exposed from the magnetic body; and 
 forming an electrode structure on the magnetic body, wherein the terminal part comprises a first area and a second area of a cross-section surface of a first end of the insulated conductive wire, wherein said first area of the cross-section surface is in contact with the magnetic body and not in contact with the electrode structure and said second area of the cross-section surface is in contact with the electrode structure and not in contact with the magnetic body, and wherein at least one portion of the electrode structure is disposed over the bottom surface of the recess and in contact with the internal conductor of the second portion of the terminal part of the insulated conductive wire for connecting with an external circuit. 
 
     
     
       18. The method of  claim 17 , wherein the electrode structure comprises a conductive and adhesive layer overlaying on the magnetic body and covering a first part of the second portion of the terminal part of the insulated conductive wire, wherein a second part of the second portion of the terminal part of the insulated conductive wire is not covered by the conductive and adhesive layer. 
     
     
       19. The method of  claim 17 , the electrode structure further comprises a first metal layer overlaid on the second portion of the terminal part of the insulated conductive wire, wherein the electrode structure comprises a conductive and adhesive layer overlaying on said first metal layer and covering a first part of the first metal layer, wherein a second part of the first metal layer is not covered by the conductive and adhesive layer.